Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s more than only a advertising promise! Over 50 drawings of varied components served as the premise for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in common, they had been all rotationally symmetrical. This was the start line for welding machine manufacturer EWM in their mission to develop a custom automation resolution tailor-made to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all round the world for transporting liquids using centrifugal pumps. Their areas of application include refineries, energy plants and nuclear vegetation, in the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump protection valve elements mechanically. These valves are connected directly to the pumps and guarantee steady operation of the pumps to stop them working dry or being broken by cavitation during minimum flow situations. The pump protection valve is basically made up of the valve body and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone must be completely air and watertight. This is the one method to make sure correct functioning of the pump safety valve for decades to return. Normally, these elements are made using low-cost building steel DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This process was previously performed manually, however, due to each the scarcity of fine welders and rising high quality assurance necessities, automation of this step was essential. The internal diameter of the valve bodies and the cone diameters were between 32 mm and four hundred mm. The elements being moved additionally differed vastly in weight, ranging from a few hundred grams to two and a half tonnes. But all the parts had one thing in widespread: they were all rotationally symmetrical, making them good for an automated course of. With this as a beginning point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly turned clear that solely a robot system would match the invoice when it came to automating this particular course of. Having to take care of so many various part sizes was a cause for concern. Large elements require a big welding positioner. เกจวัดแรงดันน้ำ10บาร์ , nevertheless, can not provide the dynamics required for the smaller parts. This quickly gave rise to the idea of three processing stations: one large L-positioner with tilting operate for the large valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench without positioners for some other elements. The top of the building was additionally a specific problem. The components had to have the power to be placed on the benches with the crane. The crane hook, nevertheless, was only roughly three metres high – extraordinarily small for an industrial utility. To assure accessibility while ensuring extraction, either the extraction hood or the system benches had been made to be cellular. The robot was fitted in a particularly small sales space within the centre between the three stations. This sales space also consists of both the power source and a Titan XQ. These are positioned behind the L-positioner at the giant processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all essential positions can additionally be ensured because of the extreme arm size of two metres and optimised house inside the booths.
Special torch for extreme spaces
Each valve body is provided with a cone information which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily difficult. For handbook welding, the welder is unable to see the weld seam and as an alternative should rely on their expertise. Even for automated welding, these areas are very unusual. EWM was solely capable of settle for this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a particular building with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special utility needed to be tailored to accommodate this uncommon design: as a result of dilution between the father or mother metallic and the armouring needs to be as low as possible, solely slightly energy is used. This ensures safe heat dissipation despite the acute welding torch dimensions.
Secure welding results via outlined parameters
As the parts have been rotationally symmetrical, it was simple to show the parts; instructing is at all times based mostly on the identical applications. Even new parts could be welded routinely rapidly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot control will deal with the rest. The desired welding result’s always guaranteed because the welding process is outlined with all of its parameters. The quality can be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and intended for one specific software, Schroeder is already thinking of recent ideas and makes use of. Schroeder would like to check out some of the varied welding procedures that are included within the Titan XQ welding machine as commonplace. This will enable to additional optimise totally different sorts of surfaced parts. Schroeder are also trying to increase and enhance the range of welding tasks.
There are lots of of Schroeder Valves installed in plants in southern Africa defending property at firms like Sasol, Eskom, Mondi and Sappi to call a number of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or telephone 011 397 2833 or 0861 103 103 to be taught more.
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